MEET POLYESTER
FROM:
Synthetic polymers derived from petroleum-based chemicals.
IS IT SUSTAINABLE?
No.
IS IT DURABLE?
Yes.
IS IT BREATHABLE?
No.
IS IT WARM?
No, it’s hydrophobic.
HISTORY:
Polyester was first discovered and developed in the 1930s by British chemists John Rex Whinfield and James Tennant Dickson. They were working at the Calico Printer’s Association in Manchester, England, when they created a polyester fiber called Terylene, later known as Dacron. In the late 1940s, the American chemical company DuPont introduced polyester to the market under the brand name “Dacron®.” It quickly gained popularity as a versatile and affordable synthetic fiber. Polyester’s popularity soared in the 1950s and 1960s. It is known for its strength, durability, wrinkle resistance, and easy care characteristics. Polyester became useful in many different industries, like making clothes, home items like bedsheets and curtains, and even carpets.
Over the years, technological advancements have led to improvements in polyester production. These advancements have enhanced the fiber’s quality, softness, dyeability, and moisture-wicking properties, making it more versatile and suitable for a wide range of applications. But since it comes from petrochemicals, some people worry about its impact on the environment. The production of polyester involves the use of non-renewable resources and energy-intensive processes. However, we are finding ways to recycle it, and recycled polyester (rPET) is becoming more popular as a more eco-friendly choice.
PRODUCTION PROCESS:
The primary materials for polyester production are petroleum-based products, specifically ethylene and terephthalic acid. The purified products are combined in a reactor and subjected to a high-temperature process known as polymerization. This process causes long chains of polyester polymer to form.
The resulting polymer, in the form of chips or pellets, is then melted at high temperatures to form a liquid called a “melt.” This melt can be processed further to create different polyester products.
The melt is put through spinnerets, which are metal plates with fine holes or slots. As the polymer passes through the spinnerets, it is forced through these tiny openings, forming continuous threads. The extruded threads are cooled rapidly, either by passing through a cooling chamber or by direct contact with air or water, causing them to solidify and become solid polyester fibers.
To enhance the strength and performance properties of the fibers, they go through a process called drawing or stretching. The solidified fibers are subjected to controlled tension or mechanical stretching, aligning the polymer chains and increasing their orientation and strength. The drawn polyester fibers are then subjected to a heat-setting process. This involves exposing the fibers to elevated temperatures, which helps them retain their stretched state and improves their stability.
The continuous fibers can be cut into desired lengths. Once the fibers are produced, they can go through treatments such as dyeing, printing, or applying special coatings to improve characteristics like colorfastness, water repellency, or flame resistance.
The polyester fibers, either as staple fibers or continuous filaments, are spun into yarns using various spinning techniques, such as ring spinning or open-end spinning. These yarns can then be further processed and woven or knitted into fabrics.
